JPH08156150A - Sandwich structure using hollow core material and manufacture of the same - Google Patents

Abstract

PURPOSE: To improve the functions of a sandwich structure using a hollow core material and to simplify the manufacturing process of the sandwich structure. CONSTITUTION: In a sandwich structure 1 using a hollow core material 2, the core material 2 is formed from an elastomer. A method for manufacturing the sandwich structure 1 is composed of a hollow core material forming process in which the hollow core material 2 is formed on one side of a supporting sheet 4 by using a mimeograph or an intaglio, a supporting sheet adhesion process in which the supporting sheet is bonded to another surface of the hollow core material 2 to obtain an intermediate structure, and a skin material adhesion process in which two skin materials 3 are bonded to the intermediate structure to obtain the sandwich structure 1.

Description

Detailed Description of the Invention

[0001]

[Object of the invention]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated structure having a honeycomb structure, which is used as a structural member for construction or a structural member for vehicles. And a method for manufacturing the same.

[0002]

BACKGROUND OF THE INVENTION Recently, a laminated structure having a honeycomb structure has been used as a structural member for construction or a structural member for vehicles. This is because the excellent function of the honeycomb structure such as light weight and high strength is focused on, and the surface and the back surface of the hollow core material of the honeycomb structure are made of two surface layer materials made of a metal plate such as aluminum or a wood plate,
Each of them is composed of a surface layer.

However, when it is used as a structural member for construction or a structural member for vehicles, it is required to have other functions such as heat insulating property, soundproof property, and vibration-proof property, so that it has an appropriate mass so as not to be unnaturally lightened. It is also required to have a feeling. It is impossible to deal with such a demand only with the honeycomb structure, and some other solution is desired.

Further, in forming the hollow core material having the honeycomb structure, if the material itself is made of a metal such as aluminum, casting, pressing (punching),
Methods such as foil bonding molding, and injection molding or the like are generally used if the material itself is made of synthetic resin. However, in any of these molding methods, burrs on the front and back surfaces of the hollow core material that are to be bonded to the surface layer material are removed, and secondary processing such as cutting and polishing to finish to a certain flatness ( Pretreatment prior to the step of adhering to the surface layer material is required.

Further, when the hollow core material is molded by the above-mentioned molding method, the raw materials are limited to those having the same composition and the same property, and have a composite property in which a plurality of materials having different compositions and different properties are combined. It is impossible to form a hollow core material. Further, the hollow core material that can be molded by these molding methods is generally limited to a continuous shape, and it is not possible to mold a hollow core material in which some elements as shown in FIG. However, even if there is a possibility of molding, it is impossible because the molds must be separately raised, and it is difficult to perform positioning when adhering to the surface layer material.

[0006]

The present invention was devised on the basis of the recognition of such a background, and by improving the material of the hollow core material and adopting a new molding method for the hollow core material, The present invention proposes a sandwich structure using a novel hollow core material, which solves the above problems, improves functionality, and simplifies the manufacturing process, and a manufacturing method thereof.

[0007]

Configuration of the Invention

[Means for Achieving the Object] That is, a sandwich structure using the hollow core material according to claim 1 is a laminated structure in which the front surface and the back surface of the hollow core material are respectively surface layers by two surface layer materials. The core material is characterized by being formed of an elastomer.

A sandwich structure using the hollow core material according to claim 2 is characterized in that, in addition to the above requirements, the hollow core material is directly or indirectly bonded to the surface layer material. It is a thing.

Further, in the sandwich structure using the hollow core material according to claim 3, in addition to the requirements of claim 2, the laminated structure has a carrying sheet on at least one of the front surface and the back surface of the hollow core material. It is characterized in that the surface layer material is formed as a surface layer on an intermediate structure formed by adhering.

A sandwich structure using the hollow core material according to claim 4 is characterized in that, in addition to the requirements of claim 3, the carrier sheet is made of a hot-melt material. is there.

Further, in the sandwich structure using the hollow core material according to claim 5, in addition to the above-mentioned requirements, the laminated structure is a structural member for construction or a structural member for vehicles in which the hollow core material has a honeycomb shape. It is characterized by something.

Further, in addition to the above requirements, the sandwich structure using the hollow core material according to claim 6 is characterized in that the hollow core material is formed of a polyurethane elastomer.

Furthermore, the method for manufacturing a sandwich structure using the hollow core material according to claim 7 is a method for manufacturing a laminated structure in which the front surface and the back surface of the hollow core material are surface layers of two surface layers respectively. In the method for producing a laminated structure, a stencil plate or intaglio plate is used, and a hollow core material forming step of forming a hollow core material on one surface of a carrying sheet by pouring an elastomer liquid raw material into these holes or recesses, A carrier sheet bonding step of further bonding a carrier sheet to the other surface of the hollow core material to obtain an intermediate structure, and two surface layer materials are respectively bonded to the front surface and the back surface of the intermediate structure to form a sandwich structure. And a surface layer material adhering step for obtaining the above.

Furthermore, a method for manufacturing a sandwich structure using a hollow core material according to claim 8 is a method for manufacturing a laminated structure in which the front surface and the back surface of the hollow core material are respectively surface layers with two surface layer materials. In the method for producing a laminated structure, a stencil plate or an intaglio plate is used, and a hollow core material is formed on one surface of a carrying sheet by pouring an elastomer liquid raw material into these holes or recesses to obtain an intermediate structure. It is characterized by comprising a core material forming step and a surface layer adhering step of adhering two surface layer materials to the front surface and the back surface of the intermediate structure to obtain a sandwich structure. is there.

Further, in the method for manufacturing a sandwich structure using the hollow core material according to claim 9, in addition to the requirements according to claim 7 or 8, the carrier sheet is made of a hot melt material. It is characterized by.

Further, in the method for manufacturing a sandwich structure using the hollow core material according to claim 10, in addition to the requirements according to claim 7, 8 or 9, the stencil plate or the intaglio plate may be separately or individually formed. It is characterized in that a plurality of sheets are used by combining the above. Then, the object of the invention is to be achieved by using the constitution of the invention described in each of these claims.

[0017]

The sandwich structure using the hollow core material according to the first aspect of the present invention has a structure in which the hollow core material is formed of an elastomer. As a result, in addition to the basic function provided by the shape of light weight and high strength, various functions such as heat insulating property, soundproofing property, vibration damping property and mass feeling provided by using the elastomer as the material can be exhibited.

The sandwich structure using the hollow core material according to the second aspect of the invention has a structure in which the hollow core material is directly or indirectly bonded to the surface layer material. As a result, when the hollow core material is directly bonded to the surface layer material, a sandwich structure having the same structure as the conventional one and having the above-mentioned various functions can be obtained. On the other hand, when the hollow core material is indirectly bonded to the surface layer material, the various functions are promoted by selecting the inner layer material interposed between the hollow core material and the surface layer material, It is possible to strengthen the adhesion between the hollow core material and the surface layer material.

Further, in the sandwich structure using the hollow core material according to claim 3, the surface layer material is used as a surface layer with respect to an intermediate structure body in which a carrier sheet is adhered to at least one of the front surface and the back surface of the hollow core material. It is configured by doing. As a result, in addition to having the above-mentioned functions, it becomes possible to promote the above-mentioned functions on the side to which the carrier sheet is adhered by selecting the carrier sheet and to strengthen the adhesion between the hollow core material and the surface layer material.

Further, in the sandwich structure using the hollow core material according to the fourth aspect, the carrier sheet is made of a hot melt material. When bonding the hollow core material and the surface layer material by this, if the supporting sheet is bonded while heating, a part of the hot melt material is melted, and a part of the hot melt is a hollow core material and It comes to be welded to the surface layer material and contributes to the strengthening of the adhesion between them.

Furthermore, the sandwich structure using the hollow core material according to claim 5 has a structure in which the laminated structure is a structural member for construction or a vehicle structural member in which the hollow core material has a honeycomb shape. By making the hollow core material a honeycomb shape by this, it is possible to achieve weight reduction and high strength, and in the structural member for construction or the structural member for vehicle, which is required to have heat insulating properties, soundproof properties, vibration damping properties and a sense of mass. Various functions come to be exhibited.

Furthermore, the sandwich structure using the hollow core material according to claim 6 has a structure in which the hollow core material is formed of a polyurethane elastomer. As a result, the above-mentioned various functions are more remarkably exhibited, and the hollow core material can be molded easily and quickly.

Furthermore, the method for producing a sandwich structure using the hollow core material according to claim 7 is a hollow core material in which a hollow core material made of an elastomer liquid raw material is formed on one surface of a carrier sheet by using a stencil plate or an intaglio plate. A molding step, a supporting sheet is adhered to the other surface of the hollow core material to obtain an intermediate structure, and a supporting sheet adhering step, and a surface layer material is adhered to the front and back surfaces of the intermediate structure to obtain a sandwich structure. And a surface layer material adhering step. As a result, at least one of the supporting sheet and the hollow core material is bonded at the same time when the hollow core material is molded, which contributes to a reduction in the number of steps (step time), and in addition to the hollow core material through the supporting sheet. Adhesion with the surface layer material facilitates and ensures the adhesion of both.

Furthermore, in the method for producing a sandwich structure using a hollow core material according to claim 8, a hollow core material made of an elastomer liquid raw material is formed on one surface of a carrier sheet by using a stencil plate or an intaglio plate to form an intermediate structure. It comprises a hollow core material forming step of obtaining a body and a surface layer adhering step of adhering a surface layer material to the front surface and the back surface of the intermediate structure body to obtain a sandwich structure body. As a result, the bonding between the carrier sheet and the hollow core material is performed at the same time when the hollow core material is molded, and since the carrier sheet bonding step is omitted, the number of steps (process time) can be reduced, and By adhering the hollow core material and the surface layer material via the carrier sheet, the both can be easily and reliably adhered.

Further, in the method for manufacturing a sandwich structure using the hollow core material according to the ninth aspect, the carrier sheet is made of a hot melt material. As a result, the same action of the invention as that brought about by the structure of claim 3 is obtained, and since the carrier sheet itself serves as an adhesive medium, an adhesive agent or the like for adhering the hollow core material and the surface layer material to each other can be obtained. It is also possible to omit the coating step.

Furthermore, the method for manufacturing a sandwich structure using a hollow core material according to a tenth aspect of the present invention has a structure in which a plurality of stencil plates or intaglio plates are used individually or in combination thereof. This makes it possible to form composite hollow core materials that combine multiple materials with different compositions and properties, as well as relatively thick hollow core materials and complex shapes that cannot be formed with a single stencil or intaglio plate. The hollow core material can be molded.

[0027]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A sandwich structure using the hollow core material of the present invention and a method for manufacturing the same will be specifically described below with reference to the drawings. In the following description, the basic structure of the sandwich structure using the hollow core material of the present invention will be described first, and then another embodiment of the sandwich structure of the present invention having a partially different structure will be described. After mentioning, taking the sandwich structure of the basic configuration as an example,
A method for manufacturing a sandwich structure using the hollow core material of the present invention will be described.

In the figure, reference numeral 1 is a sandwich structure using the hollow core material of the present invention, which can be widely used as various structural members for vehicles or structural members for vehicles. Specifically, it is applied as a structural member for doors such as doors and door fittings, wall materials or floor materials, and as a structural member for vehicles, as structural members such as doors and bodies for automobiles and trains. To be done. In addition, as structural members for airplanes, ships, rockets and artificial satellites,
It can also be applied as a structural member of various cases such as a large refrigerator or freezer, a vehicle-mounted container, and the like.

First, the basic structure of the sandwich structure 1 using the hollow core material of the present invention will be described with reference to the embodiments shown in FIGS. Sandwich structure 1 of the present invention
Is basically configured by including a hollow core material 2 having a hollow portion 2a and two surface layer materials 3 covering a front surface 2b and a back surface 2c of the hollow core material 2. 1 to 3
In the embodiment shown in FIG. 2, a hollow core material 2 and a surface layer material 3 are further added.
A carrier sheet 4 is provided between the and.

Each of these constituent members will be described more specifically below. The hollow core material 2 is formed of an elastomer as a characteristic configuration of the present invention, and its shape is, for example, a honeycomb shape as shown in FIGS. 1 and 2, and has a large number of hollow portions each having a planar hexagonal shape. 2a is formed. The elastomer means a rubber-like elastic body, and a polyurethane elastomer is used as an example in the present invention.

This polyurethane elastomer is composed of a mixed solution of a prepolymer and polyisocyanate, and is cured by heating it. Particularly, as a polyurethane elastomer to be supplied by spraying from a nozzle, Nippon Synthetic Chemical Co., Ltd. Solvent-free quick-hardening urethane resin manufactured by Kogyo Co., Ltd., for example, trade name Efletane. It is desirable to heat the elastomer liquid raw material P before spray mixing with a nozzle, and it cures in about 20 seconds gel time. It is also possible to add a solvent to this in order to adjust the viscosity and hardness.
Further, as the polyurethane elastomer, a mixture of Nipolan (registered trademark) of Nippon Polyurethane Industry Co., Ltd., which is a prepolymer, and Pandex (registered trademark) of Dainippon Ink and Chemicals, Inc., which is a polyisocyanate,
In addition, SX-320A & B manufactured by Mitsui Toatsu Chemicals, Inc. can be used. It is also expected that it is necessary to prevent the outflow from the stencil 5 or the intaglio 6 which will be described later.
Therefore, it is preferable to mix a thickener with these raw materials.

As a concrete example of the thickener, Nippon Aerogi
There is AEROSIL (registered trademark) manufactured and sold by Le Co., Ltd.
It This is the highest purity silica (S
iO ₂99.8%), and whether it is ultrafine particles of 7-50 mμ
It is a harmless substance with high surface area and high dispersibility.
It This AEROSIL® has on the surface
Addition of a small amount by the action of hydrogen bridge bond of silanol group
Necessary for processing liquid substances such as polyester and epoxy resin.
As a thickener, it can give the necessary rheological properties.
It has the function of. Also, it is limited to the above AEROSIL
Of course, it is also possible to add other fillers.
is there.

Further, a photocurable resin may be applied as another elastomer. Here, among the photocurable resins, an ultraviolet curable resin which is cured in a short time by irradiation with ultraviolet rays will be described below as an example. In selecting the ultraviolet curable resin, a transparent or translucent resin is used before and after curing so that ultraviolet rays reach deep inside the hole 5a of the stencil 5 or the recess 6a of the intaglio plate 6. Moreover, in the present invention, the cured product has an appropriate elasticity, and has excellent mechanical properties such as tensile strength, tear strength, wear resistance, etc., and further has heat insulating property, soundproofing property or vibration damping property, suitable mass feeling, etc. Apply UV curable resin that also has the functions required for the intended purpose. In this case, in order to improve the tear strength, a filler such as short fibers may be mixed in the ultraviolet curable resin to the extent that curing is not hindered.

The shape of the hollow core material 2 is not limited to the above-mentioned honeycomb shape, but the lattice shape as shown in FIG.
A circular hole shape as shown in FIG. 4B, a rhombus shape as shown in FIG. 4C, a scale-like shape as shown in FIG.
A shape obtained by combining trapezoids as shown in (e), a corrugated shape as shown in FIG. 4 (f), or a shape shown in FIG. 5 (a).
5 (b) in which the vertical and horizontal directions are arranged in a staggered manner, as shown in FIG. 5 (b), concentric shapes as shown in FIG. 5 (c), and FIG. Various shapes such as the radial shape shown in FIG. 5A and the spiral shape shown in FIG.

Further, in each of the above-mentioned embodiments, the hollow core material 2 is constituted by one continuous member. However, as shown in FIG. 6A, a plurality of elements constituting the hollow core material 2 are divided. It is also possible to use a hollow core material having the shape of the sandwich structure 1 as shown in FIG. 6 (b).
Considering the size of the load on the hollow part 2a
It is also possible to adopt a configuration in which the size of the is different. In addition, as shown in FIG. 6 (c), the hollow portion 2a is used to
It is also possible to fill or arrange another functional member 20 such as a heat insulating material or a vibration isolator, which supplements the function of the sandwich structure 1, or as shown in FIG. A partition 21 is provided for the portion 2a, and the partition 2
It is also possible to divide the hollow portion 2a into upper and lower parts by 1 and further increase the mechanical strength.

The surface layer material 3 for covering the front surface 2b and the back surface 2c of the hollow core material 2 may be made of metal such as aluminum, iron, stainless steel, wood, glass, synthetic resin, etc., depending on the purpose of use. In this case, if the material of the hollow core material 2 is different between the front surface 2b side and the back surface 2c side, the shape such as the thickness is changed, and the color, hardness, elasticity, etc. are different. It is also possible to make it.

The surface layer material 3 can be directly adhered to the hollow core material 2 through an adhesive or the like, but the carrier sheet 4 is interposed between the surface layer material 3 and the hollow core material 2.
It is also possible to interpose them and indirectly bond them. The carrying sheet 4 can be provided on both the front surface 2b and the back surface 2c of the hollow core material 2 as in the embodiment shown in FIGS.
It is also possible to adopt a configuration in which it is provided on either one of b and the back surface 2c. The intermediate structure A is defined in this specification as having the carrier sheet 4 bonded to at least one of the front surface 2b and the back surface 2c of the hollow core material 2.

As the carrier sheet 4, a non-woven fabric or a film-like hot melt material can be used as an example. When such a hot melt material is used, a part or all of this hot melt material is melted. ,
It is also possible to enhance the adhesion between the hollow core material 2 and the surface layer material 3. Further, the carrying sheet 4 can be composed of a functional member having excellent heat insulating properties, soundproofing properties, vibration damping properties and the like, and does not have its own adhesive action like the above-mentioned hot melt, but has an adhesive carrying ability. It is also possible to apply a member which is excellent in the above and contributes to strengthening the adhesion with the surface layer material 3.

Next, a method of manufacturing a sandwich structure using the hollow core material of the present invention for manufacturing the sandwich structure 1 thus constructed will be described. In the manufacturing method of the present invention, the stencil 5 or the intaglio 6 is used, and
a or the concave portion 6a of the intaglio plate 6, a hollow core material forming step of forming the hollow core material 2 on one surface of the carrying sheet 4 by pouring the elastomer liquid raw material P, and further carrying on the other surface of the hollow core material 2. A supporting sheet bonding step of bonding the sheet 4 to obtain the intermediate structure A, and the intermediate structure A
And a back surface step of obtaining the sandwich structure 1 by bonding two surface layer materials 3 to the front surface and the back surface, respectively. In the manufacturing method of the present invention, it is possible to omit the supporting sheet adhering step, and in the case of such a structure, one having the hollow core material 2 formed on one surface of the supporting sheet 4 is an intermediate product. It becomes structure A.

The structure and production of the stencil plate 5 and the intaglio plate 6 used in the hollow core material forming step will be first described below, and then the hollow core constituting the manufacturing method of the present invention will be described with reference to the examples of the basic structure. The material forming step, the carrier sheet adhering step, and the surface layer adhering step will be described in order.

[I] Fabrication of Stencil and Intaglio (i) Fabrication of Stencil First, the construction of the stencil 5 will be described before starting the description of the fabrication of the stencil 5. The most basic one of the stencil 5 used in the present invention is, as an example of a thickness of about 1 to several mm, an iron plate having a predetermined shape according to the shape and layout of the hollow core material 2 to be formed. The holes 5a are formed by patterning. Further, it is desirable that an appropriate guide hole is formed in the stencil 5, and the guide hole is used to place the stencil 5 in a correct position or prevent a positional deviation when a plurality of stencil 5 is used. Plan. As another configuration of the stencil 5, a plurality of mounting pieces 11 corresponding to the shape of the hollow portion 2a of the hollow core material 2 to be formed as shown in FIG. 9 are prepared, and the plurality of mounting pieces 11 are appropriately arranged. It is also possible to form the stencil 5 by arranging at intervals. Incidentally, the hole 5a in the stencil 5 having such a structure serves as a gap between the plurality of mounting pieces 11.

When using the stencil 5 as described above, the mounting pieces 11 are made of a ferromagnetic material such as iron or nickel as an example, and the mounting pieces 11 are arranged at appropriate intervals. To position. As an example, an array gauge 12 as shown in FIG. 9 configured by an electromagnet is used. By the way, when installing the stencil 5 on the carrier sheet 4, as shown in FIG. 9A, the mounting piece 11 is sucked by the array gauge 12, and the carrier sheet is sucked with the mounting piece 11 sucked. 4 is transferred. Then, the magnetic force applied to the array gauge 12 is released, or the mounting piece 11 is mounted on the carrying sheet 4 in the opposite direction as shown in FIG. 9B.

Further, in mounting such a stencil 5 on the base 10, the adhesion between the stencil 5 and the base 10 and the adhesion between the stencil 5 when a plurality of stencil 5 are used in superposition are increased. Ingenuity is required. Then, as an example thereof, a method of closely contacting the stencil 5 by using magnetic force will be described. It should be noted that by utilizing such magnetic force, the stencil 5
Two methods can be selected as a method for bringing the two into close contact with each other depending on whether the base 10 side has a magnetic force or the stencil 5 side has a magnetic force. Here, a case where a magnetic force is given to the base 10 side most suitable for actual use will be described. In this case, the base 10 is composed of, for example, an electromagnetic chuck widely used as a work holding device for a surface grinder,
Thus, the stencil 5 to be adsorbed is constituted by a relatively thin iron plate or the like having the above-mentioned thickness dimension. The base 10
Of course, a permanent magnet chuck or a permanent magnet, which can be expected to have the same effect, can be used.

As a method for forming the holes 5a in the stencil 5, an etching method can be considered as an example. That is, in the case of etching, first, a plurality of thin plates are prepared, and the thin plates are etched to form the holes 5a having the same shape and the same pattern in each thin plate. Then, the stencil 5 is produced by laminating the thin plates having the holes 5a formed in this manner and joining them in a laminated state. Further, as another method for forming the holes 5a in the stencil 5, Japanese Patent Application No.
No. 307574 “Method for producing embossed sheet”, Japanese Patent Application No. 4-343146 “Method for producing embossed sheet”, the method of using a master mold, the method of using a photocurable resin film, and the method of sandblasting. In addition, various methods such as a method of forming a stencil 5 by forming a hole 5a on a metal plate, a resin plate, etc. by a method such as wire cutting, laser, punching, and pressing can be used.

As a method of adhering the base 10 and the stencil 5 or between the stencil 5 and the method of utilizing such magnetic force, spraying mist-like water droplets between the stencil 5 and freezing it. To achieve close contact between the stencil 5 and, in addition to this, drop water droplets or a few drops of adhesive liquid for temporary adhesion between the stencil 5 and superimpose them to achieve close contact. Various contacting means can be adopted, such as by providing a mechanical engaging means separately between the stencil or the stencil 5 to achieve close contact. In addition, the stencil 5 in contact with the carrying sheet 4
For example, the base 10 composed of a permanent magnet
Needless to say, in the case where the supporting sheet 4 is sandwiched by the magnetic force of the stencil 5 and the base 10, it is necessary to support the magnetic metal on at least the surface of the stencil 5.

(Ii) Fabrication of intaglio plate Next, the construction of the intaglio plate 6 and its fabrication method will be described.
When the intaglio plate 6 is composed of only one plate, it can be formed to be slightly thicker than the stencil plate 5, but when the stencil plate 5 is placed on the intaglio plate 6 for use. Is preferably of substantially the same thickness and material as the stencil 5. As for the method of forming the recess 6a in the intaglio 6, various methods described in the section (i) Fabrication of stencil can be adopted, and the details thereof will be omitted here to avoid duplication.

10 and 11 show two types of intaglio plates 6 having different structures from those of the intaglio plate 6 shown in FIG. Of these, the intaglio plate 6 shown in FIG.
The hard material 14 suitable for forming a is laminated, and the recess 6a is formed by performing a process such as etching or sandblasting. Incidentally, when the recess 6a is formed by etching, the hard material 14 is made of metal or the like which is easily etched by the etching, and when the recess 6a is formed by sandblasting or the like,
It is made of a material suitable for sandblasting such as glass and ceramics.

In the intaglio plate 6 shown in FIG. 11, the bottom portion of the recess 6a is formed to have an extremely thin wall thickness (in other words, the intaglio plate 5 has a shape such that a part of the hole 5a of the stencil 5 is continuous). It was formed. As a material for forming the intaglio plate 6, an appropriate material such as metal or silicone rubber can be applied. Considering that the intaglio plate 6 is wound in a roll shape as shown in FIG. 11, It is desirable to use a relatively flexible material.

[II] Hollow Core Material Forming Step Next, the steps until the hollow core material 2 is formed by using the stencil 5 or the intaglio plate 6 will be described. In the following description, after the stencil 5 or the intaglio plate 6 is placed on the base 10, the carrying sheet 4 is set "bearing sheet rear placement".
In the case of, the carrier sheet 4 is first placed on the base 10,
Description will be made separately for the case of "preliminary placement of the carrier sheet" in which the stencil 5 is installed on it. In the following description, the hollow core material 2 having the basic structure shown in FIGS. 1 to 3 is taken up and the hollow core material 2 having the structure is molded, and a combination of the stencil 5 and the intaglio plate 6 is shown. , Or a case where two stencil plates 5 are stacked and used.

(A) When the carrier sheet is placed afterward (1) Installation of stencil or intaglio (see FIG. 12 (a)) First, the stencil 5 or intaglio 6 is installed on the base 10. At this time, between the stencil 5 or the intaglio 6 and the base 10, there is provided a means for bringing them into close contact with each other, for example, a suction means utilizing an electromagnetic chuck.
Are closely supported by the base 10. In the illustrated embodiment, the stencil 5 is used and the stencil 5 is installed on the base 10. When the stencil 5 is installed, the guide holes and the like formed on the stencil 5 are not shown. Use it to perform alignment.

(2) Injection of elastomer liquid raw material, squeegee treatment (see FIGS. 12 (a) and 12 (b)) Next, the elastomer liquid raw material P is applied to the hole 5a or the recess 6a of the stencil 5 or the intaglio 6 as described above. inject. Then, a predetermined amount of the elastomer liquid raw material P is added to the holes 5 of the stencil 5.
a or the concave portion 6a of the intaglio plate 6 is poured,
Using the squeegee tool 30 as shown in (b), the hole 5a
Alternatively, the elastomer liquid raw material P existing outside the upper surface of the recess 6a is removed. At this time, of the elastomer liquid raw material P in each hole 5a or the recess 6a, the hole 5
a or a portion of the material existing immediately below the upper surface of the recess 6a is partially removed from the elastomer liquid raw material P and the hole 5a of the stencil 5.
Alternatively, due to the surface tension, contact angle, wetting, and the like with the recess 6a and the tip of the squeegee tool 30, the tip of the squeegee tool 30 may be dragged and removed together.

(3) Installation of stencil, injection of elastomer liquid raw material, squeegee treatment (see FIGS. 12C and 12D) Next, another stencil 5 is installed on the stencil 5 or the intaglio plate 6. Then, the elastomer liquid raw material P is injected into the holes 5a of the stencil 5, and the squeegee tool 30 is used to perform the squeegee treatment as described above. Incidentally, when a plurality of stencil plates 5 are overlapped and used in this way, it becomes possible to mold the hollow core member 2 having a relatively large thickness, and by making the shape of the hole portions 5a in each stencil plate 5 different, A hollow core material 2 having a more complex property composed of a plurality of materials having different compositions is formed by molding the hollow core material 2 having a complicated shape or by changing the kind of the elastomer liquid raw material P to be injected for each stencil 5. It becomes possible to mold. If the wall thickness is not so required, it is of course possible to mold the hollow core material 2 with only one stencil plate 5.

(4) Installation of support sheet, pressurization / heating (Fig. 1
2 (e)) In this way, the squeegee process is performed, and the carrier sheet 4 is placed on the upper surface of the stencil 5 from which the excess elastomer liquid raw material P has been removed. Then, in this way, on the base 10, the stencil 5 or intaglio 6 and then another stencil 5,
Further, the support sheet 4 laminated thereon is pressed from above and below by using, for example, a pressing device, and further heated, so that the elastomer liquid raw material P is cured until the plate can be deplated.

(5) Plate-removing and reverse mounting (see FIG. 12 (f)) Then, when the elastomer liquid raw material P is cured to a plate-removable state and the hollow core material 2 is formed, the carrying sheet 4
The plate is removed from the stencil plate 5 or the intaglio plate 6 and is turned upside down and placed on the base 10 so that the hollow core material 2 faces upward.

(B) In the case of preliminarily placing the carrying sheet, that is, in this case, since the intaglio 6 cannot be used due to its structure, the stencil 5 is used. (1) Placement of the carrying sheet and installation of the stencil (see FIG. 13A) First, while placing the carrying sheet 4 on the base 10,
A stencil 5 in which holes 5a having a predetermined shape are formed in a pattern in advance is installed on the carrying sheet 4, and the stencil 5 is fixed on the base 10 with the carrying sheet 4 interposed.

(2) Injection of elastomer liquid raw material, squeegee treatment (see FIGS. 13A and 13B) Next, the elastomer liquid raw material P is injected into the hole 5a of the stencil 5. Then, when a predetermined amount of the elastomer liquid raw material P is injected, the excess elastomer liquid raw material P protruding from the upper surface of the hole 5a and existing is removed using the squeegee tool 30.

(3) Installation of stencil, injection of elastomer liquid raw material, squeegee treatment (see FIGS. 13 (c) and (d)) Next, another stencil 5 was installed on the stencil 5 and the stencil 5
The elastomer liquid raw material P is injected into the hole 5a.
Then, the squeegee tool 30 is used to perform the squeegee process as described above.

(4) Pressurization / heating, plate removal (Fig. 13 (e)
(F)) In this way, the squeegeeing process is performed, and the one in which two stencil plates 5 are laminated on the carrying sheet 4 from which the excess elastomer liquid raw material P has been removed is added from above and below using, for example, a pressing device. By pressing and further heating, the elastomer liquid raw material P is cured until the plate can be deplated. Then, the elastomer liquid raw material P is cured to a depressurizable state, and when the hollow core material 2 is molded, the two stencil plates 5 are depressurized.

[III] Carrier Sheet Bonding Step (See FIG. 14) That is, a step of bonding another carrier sheet 4 to the surface of the hollow core material 2 formed in the hollow core material molding step, on which the carrier sheet 4 is not provided. Is. For example, an adhesive is applied to the upper surface of the hollow core material 2 placed on the base 10 so that the carrying sheet 4 is on the lower side in the hollow core material forming step, and the other carrying sheet 4 is covered thereon. Make sure to press bond. Note that the adhesion in this case is not necessarily strong. For example, when the carrier sheet 4 is formed of a hot-melt material, the carrier sheet 4 is melted in the surface layer material bonding step described later. It is also possible to make it a very weak temporary adhesive in anticipation of the welding action by. In addition, the front surface 2b and the back surface 2 of the hollow core material 2
When the carrier sheet 4 is bonded to only one surface of c to form the intermediate structure A, this step is omitted.

[IV] Surface Layer Material Adhesion Step (See FIG. 15) Next, the surface layer material 3 is further adhered to the front surface and the back surface of the intermediate structure A manufactured by the above-mentioned supporting sheet adhesion step. Also in this case, an adhesive is used, and the adhesive is applied to the carrier sheet 4 side or the surface layer material 3 side, and the surface layer material 3 is adhered to the front surface and the back surface of the intermediate structure A so as to be pressure-bonded. To do. When the carrier sheet 4 is made of a hot melt material, it is pressed and bonded while being heated. That is, as a result of this, the carrier sheet 4 is melted and welded to the hollow core material 2 and the surface layer material 3, so that when a sufficient adhesive force can be obtained by this welding, the interposition of an adhesive is not always necessary.

The surface layer material 3 is thus adhered to manufacture the sandwich structure 1 of the present invention. However, in order to obtain a product, the surplus adhesive is further removed, It is necessary to remove dirt, burrs and the like, fit a frame material around the periphery, attach a handle and the like, and further, perform a finishing process such as painting if necessary.

[0062]

The sandwich structure using the hollow core material and the method for producing the same according to the present invention have the above-mentioned constitutions. By having such constitutions, various effects as described below are obtained. Is demonstrated. A sandwich structure using the hollow core material according to claim 1,
The hollow core member 2 is made of an elastomer. As a result, in addition to the basic function provided by the shape of light weight and high strength, various functions such as heat insulating property, soundproofing property, vibration damping property and mass feeling provided by using the elastomer as the material can be exhibited.

The sandwich structure using the hollow core material according to claim 2 has a structure in which the hollow core material 2 is directly or indirectly bonded to the surface layer material 3. Thus, when the hollow core material 2 is directly adhered to the surface layer material 3, the sandwich structure 1 having the same structure as the conventional one and having the above-mentioned functions can be obtained. Become. On the other hand, when the hollow core material 2 is indirectly bonded to the surface layer material 3, the above-mentioned various functions are achieved by selecting the inner layer material interposed between the hollow core material 2 and the surface layer material 3. It is possible to promote or strengthen the adhesion between the hollow core material 2 and the surface layer material 3.

Furthermore, the sandwich structure using the hollow core material according to claim 3 has an intermediate structure A in which a carrier sheet 4 is bonded to at least one of the front surface 2b and the back surface 2c of the hollow core material 2. The surface layer material 3 is formed as a surface layer. As a result, in addition to having the above-mentioned various functions, it is possible to promote the various functions by selecting the supporting sheet 4 on the side to which the supporting sheet 4 is adhered and to strengthen the adhesion between the hollow core material 2 and the surface layer material 3. It will be possible.

Furthermore, in the sandwich structure using the hollow core material according to the fourth aspect, the carrying sheet 4 is made of a hot melt material. Thus, when the hollow core material 2 and the surface layer material 3 are bonded together, if the carrier sheet 4 is bonded while heating, a part of the hot melt material is melted and a part of the hot melt is hollow. It comes to be welded to the core material 2 and the surface layer material 3, and contributes to strengthening the adhesion between the both.

Furthermore, in the sandwich structure using the hollow core material according to the fifth aspect, the laminated structure is a hollow core material 2
Is a structural member for construction or a structural member for vehicles having a honeycomb shape. By making the hollow core material 2 into a honeycomb shape, it is possible to reduce the weight and increase the strength.
The above-mentioned various functions will be exhibited in the structural member for construction or the structural member for vehicle which is required to have heat insulating properties, soundproof properties, vibration damping properties and a sense of mass.

Furthermore, the sandwich structure using the hollow core material according to claim 6 has a structure in which the hollow core material 2 is formed of a polyurethane elastomer. As a result, the above-mentioned functions are more remarkably exhibited, and the hollow core material 2 can be molded easily and quickly.

Furthermore, in the method for manufacturing a sandwich structure using the hollow core material according to the seventh aspect, the hollow core material 2 made of the elastomer liquid raw material P is provided on one surface of the carrier sheet 4 using the stencil 5 or the intaglio plate 6. The forming step of the hollow core material, the step of adhering the supporting sheet 4 to the other surface of the hollow core material 2 to obtain the intermediate structure A, and the surface layer material on the front surface and the back surface of the intermediate structure A. 3 is adhered to obtain the sandwich structure 1, and a surface layer material adhering step is included. As a result, at least one of the supporting sheets 4 and the hollow core material 2 is bonded to each other by the hollow core material 2
Is performed at the same time as the molding, and contributes to the reduction of the number of processes (process time), and also the hollow core material 2 through the carrying sheet 4.
By adhering the surface layer material 3 to the surface layer material 3, the adhesion of the both becomes easy and reliable.

Furthermore, in the method for manufacturing a sandwich structure using the hollow core material according to the eighth aspect, the hollow core material 2 made of the elastomer liquid raw material P is provided on one surface of the carrier sheet 4 using the stencil 5 or the intaglio plate 6. A hollow core material forming step of forming and obtaining an intermediate structure A, and a surface layer adhering step of adhering a surface layer material 3 to the front and back surfaces of the intermediate structure A to obtain a sandwich structure 1 Has been done. As a result, the supporting sheet 4 and the hollow core material 2 are bonded at the same time when the hollow core material 2 is molded, and since the supporting sheet bonding step is omitted, the number of steps (process time) is reduced. In addition, by adhering the hollow core material 2 and the surface layer material 3 via the carrying sheet 4, the adhesion of the both becomes easy and reliable.

Furthermore, in the method for manufacturing a sandwich structure using the hollow core material according to claim 9, the carrier sheet 4 is made of a hot melt material. As a result, the same effect as the invention brought about by the structure according to claim 3 is obtained, and since the carrier sheet 4 itself also serves as an adhesive medium, the adhesion at the time of adhering the hollow core material 2 and the surface layer material 3 It is also possible to omit the step of applying the agent or the like.

Furthermore, the method for manufacturing a sandwich structure using a hollow core material according to a tenth aspect of the present invention has a construction in which a plurality of stencil plates 5 or intaglio plates 6 are used individually or in combination thereof. .
This makes it possible to form a composite hollow core material 2 in which a plurality of materials having different compositions and properties are combined, and a relatively thick hollow core material 2 that cannot be formed by a single stencil 5 or intaglio plate 6. Also, the hollow core material 2 having a complicated shape can be molded. In addition, it is assumed that the effects brought about by the configurations of the inventions described in each of these claims act synergistically, and the basic functions such as light weight and high strength are provided, and also the heat insulating property, the soundproof property, and the anti-vibration property are provided. sex,
It also has various functions such as a feeling of mass, improves its functionality, and can contribute to a reduction in manufacturing cost through simplification of the manufacturing process.

[Brief description of drawings]

FIG. 1 is an exploded perspective view showing a sandwich structure using a hollow core material of the present invention.

FIG. 2 is a plan view showing the carrying sheet and the surface layer material on the front surface side in a fractured manner.

FIG. 3 is a longitudinal side view showing the same in an enlarged manner.

FIG. 4 is a plan view showing various other embodiments in which the hollow core material has a different hollow portion shape.

FIG. 5 is a plan view showing various other embodiments of the above.

6A and 6B are a plan view and a vertical sectional side view showing other various embodiments in which the structure of the hollow core material is different.

FIG. 7 is a perspective view showing both an intermediate product and a sandwich structure manufactured by the manufacturing method of the present invention.

FIG. 8 is a vertical cross-sectional side view showing a basic configuration of a stencil plate and an intaglio plate used in a hollow core material forming step.

FIG. 9 is a skeletal longitudinal side view showing another embodiment in which the structure of the stencil is different.

FIG. 10 is a skeletal vertical sectional side view showing another embodiment in which the configuration of the intaglio plate is different.

FIG. 11 is a skeletal vertical sectional side view showing still another embodiment of the same.

FIG. 12 is a skeletal vertical cross-sectional side view showing stepwise the hollow core material molding step in the manufacturing method of the present invention.

FIG. 13 is a skeletal vertical cross-sectional side view showing another embodiment in the same manner stepwise.

FIG. 14 is a skeletal vertical cross-sectional side view showing stepwise a carrier sheet bonding step in the manufacturing method of the present invention.

FIG. 15 is a skeletal vertical sectional side view showing stepwise a surface layer material adhering step in the manufacturing method of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Sandwich structure 2 Hollow core material 2a Hollow part 2b Front surface 2c Back surface 3 Surface layer material 4 Carrier sheet 5 Hole plate 5a Hole part 6 Intaglio plate 6a Recess 10 Base 11 Placement piece 12 Array gauge 13 Base material 14 Hard material 20 Functional member 21 Partition part 30 Squeegee tool A Intermediate structure P Elastomer liquid raw material

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B29L 31:10 31:30

Claims (10)

[Claims] 1. A laminated structure in which the front surface and the back surface of a hollow core material are surface layers of two sheets respectively, and the hollow core material is formed of an elastomer. The sandwich structure used. 2. The sandwich structure using a hollow core material according to claim 1, wherein the hollow core material is directly or indirectly adhered to the surface layer material. 3. The laminated structure is formed by superimposing the surface layer material on an intermediate structural body formed by adhering a carrier sheet on at least one of the front surface and the back surface of a hollow core material. A sandwich structure using the hollow core material described in 2. 4. The sandwich structure using a hollow core material according to claim 3, wherein the carrier sheet is made of a hot melt material. 5. The hollow core material according to claim 1, wherein the laminated structure is a structural member for construction or a structural member for vehicles, in which the hollow core material has a honeycomb shape. The sandwich structure used. 6. The sandwich structure using the hollow core material according to claim 1, wherein the hollow core material is formed of a polyurethane elastomer. 7. A method for manufacturing a laminated structure comprising a hollow core material, the front surface and the back surface of which are respectively superposed by two surface layers, wherein the laminated structure manufacturing method uses a stencil plate or an intaglio plate. Hollow core material forming step of forming a hollow core material on one surface of the carrying sheet by pouring the elastomer liquid raw material into the holes or recesses, and further adhering the carrying sheet to the other surface of the hollow core material to form an intermediate structure A carrier sheet bonding step for obtaining a body, and a surface layer bonding step for bonding two surface layers to the front and back surfaces of the intermediate structure to obtain a sandwich structure, respectively. A method of manufacturing a sandwich structure using a hollow core material. 8. A method for producing a laminated structure comprising a hollow core material, the front surface and the back surface of which are respectively superposed by two surface layers, wherein the laminated structure is produced by using a stencil plate or an intaglio plate. Hollow core material forming step of forming a hollow core material on one surface of a carrying sheet by pouring an elastomer liquid raw material into the holes or recesses, and two surface layers on the front and back surfaces of this intermediate structure A method for producing a sandwich structure using a hollow core material, which comprises a step of adhering materials to each other to obtain a sandwich structure. 9. The supporting sheet is made of a hot-melt material, which is characterized in that:
A method for producing a sandwich structure using the hollow core material described. 10. The sandwich structure using a hollow core material according to claim 7, wherein a plurality of the stencil plates or the intaglio plates are used individually or in combination thereof. Manufacturing method.